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The sunroof comes complete with everything that you'll need (except tools) to make quick work of the installation. Before beginning, check the completeness of the sunroof package using the provided parts list.
Then, locate, mark and tape the proper position for the roof cutout template. Position the template flat against the roof and tape it making sure its straight and there are no creases.
Using a single-edge blade, carefully cut out the area of the paper template for the roof cut and draw the cut outline on the roof metal with a marking pen.
Drill the six holes as marked on the front of the template for the wind deflector, making sure not to damage the inside roof lining. Note: a "bit stop" can be used for safety.
Drill a "pilot hole" for the nibbler (or heavy duty sabre saw) inside the outline on the roof. Using a nibbler or sabre saw carefully cut out the metal roof along the outline. Note: a die grinder can also be used to cut out the metal roof
Next the roof ribs must be cut out along the edge of the roof metal and removed.
Mark the hard headliner using the roof metal as a guide. Using a razor knife, carefully cut out the hard headliner to match the roof cutout
On the inside, lay 3/4-inch tape around the edge of the hard headliner as a guide and cut out the headliner along the outer edge of the tape, thus making the inside headliner cutout 3/4-inch larger than the roof metal cutout.
Use the die grinder cut the support ribs 3/4-inch larger than the roof cutout as well.
Place the wind deflector in the holes drilled earlier. Using the special sealing washers and nuts provided, attach the wind deflector but do not tighten the nuts
Carefully drop the sunroof into the cutout being careful not to dent the roof metal.
Remove the "A" pillar cap and route sunroof motor wiring down the pillar and under the dash. Red wire goes to 12V(+) constant and blue goes to ign. switched (+) and if you want the roof to close when you turn the key off tap the yellow wire to the blue wire. If you don’t want it to close with ign. Just cap the yellow wire off. And black is ground. Remove the two retaining screws from the motor unit on the frame and bolt the front aluminum clamp frame part in place and then screw the motor to the aluminum frame.
Put the rear clamp frame part on and screw in one each of the enclosed nuts onto the stay bolts. Then push the frame sides on. Attach with screws provided all the way around. Note: Do not place any screws into holes with labels stuck on them because the supports for the trim frame are fastened in those holes
Place the supports in position with the upwardly flanged nose of the support engaging the gap between the mainframe and the clamping frame, attach with the fastening screws and tighten equally
Connect the operating switch to the wiring loom and make sure that it works. Close the roof, adjust the wind deflector as needed so it creates a tight seal with top and tighten the wind deflector nuts
Fit the front trim cover, guiding the wire for the operating switch through the opening provided. Beginning in the middle at the rear, attach the edge protection (pinch welting) all the way around and trim the excess with wire cutting pliers.
You’re done! If you completed this process pat yourself on the back because you just saved yourself $750 dollars! You can order from www.inalfasunroofs.com (look under folding roof) or call 1 (800) 521-9753. Expect to pay about $600 and it’s worth it.
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01-07-2006, 11:21 PM
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